Steering Gear Replacement Procedure

1. With the front wheels centered, turn the ignition switch to the locked position and remove the key from the switch. Turn the steering wheel to the left until the steering wheel security lock engages (180°). This step ensures the clock spring will not be over extended.





2. With the vehicle on the ground, remove the black trim cover at the lower left side of the instrument panel to gain access to the steering column shaft coupler. Disconnect the steering column shaft coupler from the steering gear intermediate coupler (Figure 5).

3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies.





4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then dispose of the fluid properly.





5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for the other side.





6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or MB-991113 (Figure 8).





7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU.

8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Separate the cradle plate from the vehicle.





9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10).

10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and lower the steering gear enough to allow access to the intermediate coupler roll pin.





11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out of the intermediate coupler. Remove the special tool from the intermediate coupler.

12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear from the vehicle.

13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room to install the intermediate coupler.

14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then install the intermediate coupler onto the shaft of the steering gear.

15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the intermediate coupler. Remove the special tool from the intermediate coupler.

16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10. Torque the bolts/nuts to 183 Nm (135 ft. lbs.).

17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S fluid line tube nuts to 31 Nm (275 in.lbs.).

18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side.

19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8. Torque the bolts/nuts to 165 Nm (123 ft. lbs.).

20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.).

21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.).

22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still off the ground.

23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned with the steering column coupler and assemble the couplers together.

24. Lower the vehicle so its full weight is resting on the ground.

25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them to 28 Nm (250 in. lbs.). Install the safety pin.

26. P/S fluid level adjustment, use the procedure outline, step 18.

27. FRONT TOE IN ADJUSTMENT

a. Ensure all tires are the same size and inflated to the recommended pressure.





b. Verify vehicle ride height is within specification (Figure 12).

c. Ensure the fuel tank is full and the vehicle is on a level surface

d. Center the steering wheel and lock in place with a steering wheel clamp.

NOTE:
DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING FRONT WHEEL TOE IN ADJUSTMENT.

e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°.

f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.).

g. Adjust the steering gear tie rod boots so they are not stressed.

h. Remove the steering wheel clamp.